Alkaline cell manufacturing method

Abstract

A powdered positive mixture, a powdered separator mixture, and a powdered negative mixture are filled sequentially into a mold in layers, then the layers of the positive mixture, the separator mixture and the negative mixture are compacted in the mold to form a laminated tablet. The laminated tablet is placed in a container, and is impregnated with an alkaline electrolyte queous solution. Then the container is sealed to produce an alkaline cell.

What is claimed is: 
     
       1. An alkaline cell manufacturing method comprising the steps of: sequentially filling a positive mixture powder, a separator mixture powder and a negative mixture powder into a mold;   compacting said positive mixture powder, said separator mixture powder and said negative mixture powder in said mold so as to form a laminated cell tablet;   placing said laminated cell tablet into a container;   impregnating said laminated cell tablet with an alkaline electrolyte solution; and   sealing said container so as to produce an alkaline cell.   
     
     
       2. An alkaline cell manufacturing method as recited in claim 1, wherein said positive mixture powder contains a positive active material, an electrical conductive material and a binding agent. 
     
     
       3. An alkaline cell manufacturing method as recited in claim 2, wherein said positive active material is an oxidizing agent. 
     
     
       4. An alkaline cell manufacturing method as recited in claim 3, wherein said positive active material is manganese dioxide, nickel oxide (IV), tungsten trioxide, lead dioxide, or molybdenum trioxide. 
     
     
       5. An alkaline cell manufacturing method as recited in claim 2, wherein said electrical conductive material is acetylene black, black lead, graphite or powdered nickel. 
     
     
       6. An alkaline cell manufacturing method as recited in claim 2, wherein said binding agent is carboxymethyl cellulose, polytetrafluoroethylene or carboxymethyl cellulose salt. 
     
     
       7. An alkaline cell manufacturing method as recited in claim 1, wherein said negative mixture powder contains a negative active material, an electrical conductive material and a binding agent. 
     
     
       8. An alkaline cell manufacturing method as recited in claim 7, wherein said negative active material is a hydrogen storage alloy which stores hydrogen. 
     
     
       9. An alkaline cell manufacturing method as recited in claim 8, wherein said hydrogen storage alloy is TiNi, TiNiB 0 .01, TiNiMm 0 .01, LaNi 5  or TiFe. 
     
     
       10. An alkaline cell manufacturing method as recited in claim 7, wherein said electrical conductive material is acetylene black, black lead, graphite or powered nickel. 
     
     
       11. An alkaline cell manufacturing method as recited in claim 7, wherein said binding agent is carboxymethyl cellulose, polytetrafluoroethylene or carboxymethyl cellulose salt. 
     
     
       12. An alkaline cell manufacturing method as recited in claim 1, wherein said separator mixture powder contains an electrolyte supporting material and a binding agent. 
     
     
       13. An alkaline cell manufacturing method as recited in claim 12, wherein said electrolyte supporting material is alkali-resistant and insulating. 
     
     
       14. An alkaline cell manufacturing method as recited in claim 13, wherein the electrolyte supporting material is silicon dioxide or alumina. 
     
     
       15. An alkaline cell manufacturing method as recited in claim 12, wherein said binding agent is carboxymethyl cellulose, polytetrafluoroethylene or carboxymethyl cellulose salt. 
     
     
       16. An alkaline cell manufacturing method as recited in claim 1, wherein the alkaline electrolyte aqueous solution is potassium hydroxide, sodium hydroxide, lithium hydroxide, or a mixture of two or more of potassium hydroxide, sodium hydroxide and lithium hydroxide. 
     
     
       17. An alkaline cell manufacturing method as recited in claim 1, wherein said positive mixture powder is prepared by mixing nickel hydroxide (II), acetylene black and powdered polytetrafluoroethylene in a first mixture, applying said first mixture to a nickel substrate, charging said mixture in a potassium hydroxide aqueous solution to produce a charged mixture, removing said charged mixture from said nickel substrate, drying said charged mixture, and pulverizing said charged mixture so as to produce said positive mixture powder. 
     
     
       18. An alkaline cell manufacturing method comprising steps of: (a) placing into a mold and compacting a positive mixture so as to form a compacted positive mixture layer;   (b) placing a separator mixture powder over said compacted positive mixture layer and compacting said separator mixture powder in said mold so as to form a separator mixture layer;   (c) placing a negative mixture powder over said compacted separator mixture layer and compacting said negative mixture powder in said mold so as to form a negative mixture layer;   (d) firmly compacting said positive mixture, said separator mixture and said negative mixture in said mold so as to form a laminated cell tablet;   (e) removing said laminated cell tablet from said mold and placing said laminated cell tablet in a container;   (f) impregnating said laminated cell tablet with an alkaline electrolyte aqueous solution in said container; and   (g) sealing said container so as to produce an alkaline cell.   
     
     
       19. An alkaline cell manufacturing method comprising the steps of: (a) placing into a mold and compacting a negative mixture so as to form a compacted negative mixture layer;   (b) placing a separator mixture powder over said compacted negative mixture layer and compacting said separator mixture powder in said mold so as to form a separator mixture layer;   (c) placing a positive mixture powder over said compacted separator mixture layer and compacting said positive mixture powder in said mold so as to form a positive mixture layer;   (d) firmly compacting said negative mixture, said separator mixture and said positive mixture in said mold so as to form a laminated cell tablet;   (e) removing said laminated cell tablet from said mold and placing said laminated cell tablet in a container;   (f) impregnating said laminated cell tablet with an alkaline electrolyte aqueous solution in said container; and   (g) sealing said container so as to produce an alkaline cell.   
     
     
       20. An alkaline cell manufacturing method as recited in claim 2, wherein said positive active material is manganese dioxide or nickel oxide (IV); said electrical conductive material is acetylene black; and each of said electrical conductive material and said binding agent are present in an amount of from about 3% to about 20% by weight of said positive mixture powder. 
     
     
       21. An alkaline cell manufacturing method as recited in claim 1, wherein said positive mixture powder comprises manganese dioxide, acetylene black, and carboxymethyl cellulose; said separator mixture powder comprises silicon dioxide and carboxymethyl cellulose; said negative mixture powder comprises TiNiMm 0 .01, acetylene black, and carboxymethyl cellulose; and said alkaline electrolyte solution comprises potassium hydroxide. 
     
     
       22. An alkaline cell manufacturing method as recited in claim 1, wherein said positive mixture powder comprises nickel hydroxide, acetylene black, and polytetrafluoroethylene powder; said separator mixture powder comprises alumina powder and carboxymethyl cellulose; said negative mixture powder comprises TiNiMm 0 .01, acetylene black, and carboxymethyl cellulose; and said alkaline electrolyte solution comprises potassium hydroxide. 
     
     
       23. An alkaline manufacturing method as recited in claim 4, wherein said electrical conductive material is acetylene black, black lead, graphite or powdered nickel and wherein said binding agent is carboxymethyl cellulose, polytetrafluoroethylene or carboxymethyl cellulose salt. 
     
     
       24. An alkaline manufacturing method as recited in claim 9, wherein said electrical conductive material is acetylene black, black lead, graphite or powdered nickel and wherein said binding agent is carboxymethyl cellulose, polytetrafluoroethylene or carboxymethyl cellulose salt. 
     
     
       25. An alkaline cell manufacturing method as recited in claim 14, wherein said binding agent is carboxymethyl cellulose, polytetrafluoroethylene or carboxymethyl cellulose salt.